2012 Polaris Sportsman 400 HO Service Repair Manual.pdf

1
GENERAL
2
MAINTENANCE
3
ENGINE
4
FUEL SYSTEMS
5
BODY / SUSPENSION

6
CLUTCH
7
FINAL DRIVE
8
TRANSMISSION
9
BRAKES
10
ELECTRICAL

GENERAL INFORMATION
1.1
CHAPTER 1
GENERAL INFORMATION
1
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
MODEL NUMBER INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
MODEL NUMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE IDENTIFICATION NUMBER (VIN)1.2
ENGINE DESIGNATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE AND ENGINE SERIAL NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
TRANSMISSION I.D. LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
PUBLICATION PART NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
VEHICLE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
2012 SPORTSMAN 400 H.O.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
2012 SPORTSMAN 500 H.O.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
2012 SPORTSMAN TOURING 500 HO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
2012 SPORTSMAN FOREST TRACTOR 500 EFI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
MISC. NUMBERS/CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
STANDARD BOLT TORQUE SPECIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
METRIC BOLT TORQUE SPECIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13
SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14
METRIC TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14
DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14
PAINT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15
REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15
GLOSSARY OF TERMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16

1.2
GENERAL INFORMATION
MODEL NUMBER INFORMATION
Model Number
The machine model number must be used with any correspondence regarding warranty or service.
Vehicle Identification Number (VIN)
Engine Designation Numbers
EH50PLE - Single Cylinder, Liquid Cooled,4 Stroke,
Electric Start

EH46PLE - Single Cylinder, Liquid Cooled,4 Stroke,
Electric Start
Vehicle and Engine Serial Numbers
The machine model number and serial number are
important for vehicle identification. Be sure to refer to the
engine model number and serial number (A) whenever
corresponding about an engine. This information can be
found on the sticker applied to the top side of the
crankcase (A). An additional number is stamped on the
side of the crankcase beneath the cylinder coolant elbow.
The vehicle serial number is located:
400 / 500 Non Touring Vehicles (B)
500 Touring Vehicles (C)
A 12 MN 50 AX
}
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
World
Mfg. ID
Engine
Vehicle Descriptor Vehicle Identifier

Check Digit
Model
Year
Body Style
Plant No
Individual Serial Number
* This could be either
a number or a letter
Powertrain
Emissions
4 X A M N 5 0 A * 0 P 0 0 0 0 0 0
A
B
C

1.3
GENERAL INFORMATION
1
Transmission I.D. Location
Publication Part Numbers
Year Model Model No.
Owner's
Manual PN
Parts
Manual PN
2012
Sportsman Touring 500
H.O.
A12DH50AX, AZ 9923410 9923411
2012
Sportsman Touring 500
H.O.
International
A12DH50FX 9923438 9923413
2012 Sportsman 400 H.O. A12MH46AX, AZ 9923420 9923421
2012 Sportsman 500 H.O. A12MH50AD, AQ, AX, AZ, 9923420 9923422
2012
Sportsman Forest 500
International
A12MH50FF 9923423 9923424
2012
Sportsman Forest Tractor
500 EFI International
A12MN50ET 9923430 9923431
The Transmission I.D. number is located
on the RH side transmission case; viewable
from the RH side of the vehicle.

1.4
GENERAL INFORMATION
VEHICLE SPECIFICATIONS
2012 Sportsman 400 H.O.
MODEL NUMBER: A12MH46AX, AZ, AF 

ENGINE MODEL: EH460PLE050
Category Dimension
Length 83 in. / 210.8 cm
Width 48 in. / 121.9 cm
Height 48 in. / 121.9 cm
Wheel Base 50.75 in. / 128.9 cm
Ground Clearance 11.25 in. / 28.6 cm
Dry Weight 688 lbs. / 312 kg
Front Rack Capacity 90 lbs. / 41 kg
Rear Rack Capacity 180 lbs. / 81.6 kg
Towing Capacity 1225 lbs. / 555.7 kg
Max. Weight Capacity 485 lbs. / 220 kg
Hitch Tongue Weight 120 lbs. / 34 kg
Unbraked Trailer Towing
Capacity (EU)
Data based on EU
Directive: 76/432/EEC
1786 lbs. / 810 kg
Engine
Platform Fuji 4-cycle, L/C, Single Cyl.
Engine Model Number EH460PLE050
Engine Displacement 455cc
Number of Cylinders 1
Bore & Stroke (mm) 87.9 x 75 mm
Compression Ratio 10.1:1
Compression Pressure 50-90 psi
Engine Idle Speed 1200+/- 200 RPM
Engine Max Speed 7000 RPM
Cooling System / Cap. Liquid / 2.7 qt. (2.5 L)
Overheat Warning HOT on Instrument Cluster
Lubrication Dry Sump
Oil Requirements PS-4 Plus / 2 qt. (1.9 L)
Exhaust System Single Pipe - USFS Approved
Carburetion
Carburetor model Mikuni BST 34mm
Main Jet 160
Pilot Jet / Pilot Air Jet 42.5 / 160
Jet Needle 4IB33-3
Needle Jet P-6M
Pilot / Air Screw 2.75 Turns Out (Initial setting)
Float Height 13mm from carburetor body
Fuel Delivery Fuel Pump (Impulse)
Fuel Capacity / 4.25 gal. (16 L)
Fuel Requirement
(Octane)
87 Octane (minimum)
89 Oxygenated
Electrical
Alternator Output 260 watt @ 3000 RPM
Voltage Regulator 3-Phase PDM
Pod Lighting 1x 12V / 50 Watts
Grill Lighting 2x 12v / 50 Watts
Brake Light 12V / 26.9 watts
Tail Light 12V / 8.26 watts
Ignition System DC / CDI
Ignition Timing 30° ± 2° BTDC @ 5000 RPM
Spark plug / Gap NGK BKR6E / .035 in. (.9 mm)
Battery Maintenance-Free / 12 Amp Hr.
Circuit Breakers
10A - Accessory / 10A - Fan /
15A - Main Harness
Starting Electric
Instrument Cluster
Digital Gauge LCD, Analog
Speedometer

1.5
GENERAL INFORMATION
1
JETTING CHART
Drivetrain
Transmission Type In-Line H/L/N/R/P
Transmission Fluid Type 
/ Fluid Capacity
AGL Plus 33.8 oz.
(1000 ml)
Front Gearcase Fluid Type
/ Fluid Capacity
Polaris Demand Drive Hub
Fluid / 8.97 oz / 265 ml
Gear Ratio :
Low (Front/Rear)
Rev (Front/Rear)
High (Front/Rear)
7.70:1/23.91:1
7.00:1/21.74:1
3.41:1/10.57:1
Clutch Type CVT
Belt 3211077
Steering / Suspension
Front Suspension / Shock MacPherson Strut
Front Travel 8.2 in. / 20.8 cm
Rear Suspension / Shock IRS / Progressive Rate
Rear Travel 9.5. / 24.1 cm
Turning Radius 65 in. / 165.1 cm (unloaded)
Shock Preload Adjustment
Front / Rear
Front -Non Adjustable.
Rear - Ratchet Style- Std.
Toe Out 0-1/16 in. (0-.159 mm)
Wheels / Brakes
Front Wheel Size
Front Tire Model / Size
12x5
NHS 489 / 25 x 8-12
Rear Wheel Size
Rear Tire Model / Size
12x8
NHS 489 / 25 x 10-12
Tire Air Pressure - F / R 5 psi (34.5 kPa)
Brakes - Front & Rear
Single Control
Hydraulic Disc
Brake Fluid Polaris DOT 4 Brake Fluid
ALTITUDE
AMBIENT TEMPERATURE
Below 40° F
Below 5° C
Above +40° F
Above +5° C
Meters
(Feet)
0-1800
(0-6000)
167.5 160
1800-3700
(6000-
12000)
155 150
Table 1-1: Clutching (NON EBS)
Altitude
Shift
Weight
Drive
Clutch
Spring
Meters
(Feet)
0-1800
(0-6000)
10WHF
5632283
Blue / Grey
7042202
1800-3700
(6000-
12000)
20-40 or
10RH
5631356
(20-40)
5630709
(10RH)

1.6
GENERAL INFORMATION
2012 Sportsman 500 H.O.
MODEL NUMBER: 
A12MH50AX, AZ, AD, AQ, FF, FY, FX 

ENGINE MODEL: EH500PLE13B
Category Dimension / Capacity
Length 83 in./210.8 cm
Width 48 in./121.9 cm
Height 48 in./121.9 cm
Wheel Base 50.75 in./128.9 cm
Ground Clearance 11.25 in./28.6 cm
Dry Weight 696 lbs./313 kg
(Wet weight model FF, FY,
FX)
776 lbs / 352 kg)
Front Rack/Box Capacity 90 lbs./40.8 kg
Rear Rack Capacity 180 lbs./81.6 kg
Towing Capacity 1225 lbs ./ 555.7 kg
Capacity (EU)*
NOTE: *Data based on
EU Directive: 76/432/EEC
1786 lbs. / 810 kg
Hitch Tongue Capacity
120 lbs./54.4 kg
Rear rack capacity and
tongue weight not to
exceed 180 lbs./82 kg
ENGINE
Platform Fuji Single Cylinder
Engine Model Number EH500PLE13B
Bore & Stroke (mm) 92 x 75 mm
Compression Pressure 70-90 psi W/Compression
Release
Engine Max Operating Rpm 7000 Rpm ± 200 Rpm
Cooling System / Capacity Liquid - 2.7 qt / 2.5 litre
Lubrication Pressurized Dry Sump
Oil Requirements / Capacity Polaris 2W-50 2 qt. / 1.9 litre
Exhaust System Single Pipe USFS Approved
Fuel System
Carburetor Mikuni BST 40mm
Main Jet 150
Pilot Jet 40
Jet Needle / Clip Position 6MGH1-94-3
Needle Jet X-6M
Pilot Screw 1 Turn Out (initial)
Pilot Air Jet 40
Float Height 14.7mm ± 1 (.58 ± 0.40")
Fuel Delivery Fuel Pump
Fuel Capacity / Requirement 4.25 gal US / 15.5 liters
87 Octane (minimum)
or 89 Oxygenated
Electrical
Alternator Output 260 w @ 3000 RPM
Voltage Regulator 3-phase PDM
Lights : Pod 50 watts
Grill 2 x 50 watts
Brake 26.9 watts
Tail 8.26 watts
Ignition System DC/CDI Ignition
Ignition Timing 30°± 2° BTDC @ 5000 RPM
Spark plug / Gap BKR6E / .035 in. / 0.9 mm
Battery Maintenance-Free / 12 Amp
Hr.
Circuit Protection 5 / 15 / 20 Amp Fuses
10 Amp Circuit Breaker - Fan
Starting Electric
Instrument Cluster Analog Speedo w/ LCD

1.7
GENERAL INFORMATION
1
Table 1-2: Sportsman 500 H.O.
Drivetrain
Transmission Type Drumshift - H/L/N/R/P
Transmission Capacity AGL Plus 33.8 oz.
(1000 ml)
Front Gearcase Capacity 8.97 oz. / 265 ml
Gear Ratio :
Low (Front/Rear)
Rev (Front/Rear)
High (Front/Rear)
7.70:1/23.91:1
7.00:1/21.74:1
3.41:1/10.57:1
Clutch Type PVT Non-EBS
Belt 3211077
Front Suspension / Shock A-arm / MacPherson Strut
Rear Suspension / Shock Progressive Rate Indepen-
dent - w/ 2" Coil-over
shock
Rear Travel 9.5 in. / 24.13 cm
Shock Preload Adjustment
Front / Rear
Turning Radius 65 in./165.10 cm unloaded
Toe Out 0-1/16 in / .0 - .159 mm
Wheels / Brakes
Front Wheel Size
12x5
NHS 489 / 25 x 8-12
Rear Wheel Size
12x8
NHS 489 / 25 x 10-12
Single Control
Hydraulic Disc
Brake Fluid
Polaris DOT 4 Brake
Fluid
Table 1-3: Sportsman 500 H.O. Jetting
Altitude
AMBIENT TEMPERATURE
Below 40 ° F
Below 5 ° C
+40 to +80 ° F
+5 to +28 ° C
Meters
(Feet)
0-1800
(0-6000)
155 150
1800-3700
(6000-
12000)
147.5 142.5
Table 1-4: Clutching (EBS and NON EBS)
Altitude
Shift
Weight
Drive Clutch
Spring
Meter
s
(Feet)
0-1800
(0-6000)
10 WHF
(5632283)
Green / Blue
(7041157)
1800-
3700
(6000-
12000)
10 RH
(5630709)
Green / Blue
(7041157)

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1.8
GENERAL INFORMATION
2012 Sportsman Touring 500 HO
MODEL NUMBER: A12DH50AX, AZ


ENGINE MODEL: EH500PLE13B
Length 86 in./218 cm
Width 48 in./122 cm
Height 48 in./122 cm
Wheel Base 57 in./145 cm
Ground Clearance 11 in./28 cm
Dry Weight 723 lbs./328 kg
Front Rack/Box Capacity 90 lbs./40.8 kg
Rear Rack Capacity 180 lbs./82 kg
Towing Capacity 1225 lbs. / 555.7 kg
Capacity (EU)*
NOTE: *Data based on
EU Directive: 76/432/EEC
1995 lbs. / 905 kg
Hitch Tongue Capacity 120 lbs./54.4 kg
ENGINE
Platform Fuji Single Cylinder
Engine Model Number EH500PLE13B
Compression Pressure 70-90 psi W/Compression
Release
Engine Max Operating Rpm 7000 RPM
Cooling System / Capacity Liquid - 2.7 qt / 2.5 ltr
Oil Requirements / Capacity Polaris 2W-50 2 qt. / 1.9 litre
Exhaust System Single Pipe USFS Approved
Fuel System
Carburetor Mikuni BST 40mm
Main Jet 150
Pilot Jet 40
Jet Needle / Clip Position 6MGH1-94-3
Needle Jet X-6M
Pilot Screw 2 Turns Out (initial)
Pilot Air Jet 160
Float Height 14.7mm ± 1 (.58 ± 0.40")
Fuel Delivery Fuel Pump
Fuel Capacity / Requirement 4.25 gal US / 16 liters
87 Octane (minimum)
or 89 Oxygenated
Electrical
Alternator Output 260 w @ 3000 RPM
Lights : Pod 50 watts
Grill 2 x 50 watts
Brake 2 x 8.26 watts
Tail 2 x 26.9 watts
Ignition Timing 30°± 1 BTDC @ 5000 RPM
Spark plug / Gap BKR6E / .035 in. / 0.9 mm
Battery Maintenance-Free / 12 Amp
Hr.
Circuit Breakers 5 / 15 / 20 Amp Fuses
10 Amp Circuit Breaker - Fan
Starting Electric
Instrument Cluster Analog Speedo w/ LCD

1.9
GENERAL INFORMATION
1
Table 1-5: Sportsman Touring 500 H.O.
Drivetrain
(1000 ml)
Gear Ratio :
Low (Front/Rear)
Rev (Front/Rear)
High (Front/Rear)
7.70:1/23.91:1
7.00:1/21.74:1
3.41:1/10.57:1
Clutch Type PVT EBS
Belt 3211113
shock
Front / Rear
Toe Out 0-1/16 in / .0 - .159 mm
Wheels / Brakes
Front Wheel Size
12x5
NHS 489 / 25 x 8-12
Rear Wheel Size
12x8
NHS 489 / 25 x 11-12
Single Control
Hydraulic Disc
Brake Fluid
Polaris DOT 4 Brake
Fluid
Table 1-6: Sportsman 500 H.O. Jetting
Altitude
AMBIENT TEMPERATURE
Below 40 ° F
Below 5 ° C
+40 to +80 ° F
+5 to +28 ° C
Meters
(Feet)
0-1800
(0-6000)
155 150
1800-3700
(6000-
12000)
147.5 142.5
Table 1-7: Sportsman 500 H.O. Clutching
Altitude Shift Weight
Drive Clutch
Spring
Meters
(Feet)
0-1800
(0-6000)
10 WHF
(5632283)
Green / Blue
(7041157)
1800-3700
(6000-
12000)
10 RH
(5630709
Green / Blue
(7041157)

1.10
GENERAL INFORMATION
2012 Sportsman Forest Tractor 500 EFI Specifications
MODEL NUMBER: A12MN50ET, EX
ENGINE MODEL: EH500PLE216
NOTE: *Data based on EU Directive: 76/432/EEC
Length 83 in./210.8 cm
Width 48 in./121.9 cm
Height 48 in./121.9 cm
Wheel Base 50.75 in./128.9 cm
Ground Clearance 11.25 in./28.6 cm
WET Weight 807 lbs. / 366 kg
Front Rack/Box Capacity 85 lbs./39 kg
Rear Rack Capacity 180 lbs./81.6 kg
Towing Capacity (rear) 1225 lbs ./ 555.7 kg
Towing Capacity (front) 850 lbs. / 386 kg
Capacity (EU)*
1786 lbs. / 810 kg
Hitch Tongue Capacity 120 lbs./54.4 kg
ENGINE
Platform Fuji 4 stroke, Single Cylin-
der
Engine Model Number EH500PLE216
Compression Pressure Compression Release 50-
90 psi
Engine Idle Speed 1150 ± 50 RPM
Max Engine Speed 7000 RPM
Cooling System / Capacity Liquid / 2.7 qts (2.5 L)
Overheat Warning HOT on Instrument Clus-
ter
Oil Requirements / Capac-
ity
Polaris 0W-40 / 2 qts
(1.9L)
Exhaust System Single Pipe
Fuel System
Carburetor model Electronic Fuel Injection
(EFI)
Fuel Pump (in tank assem-
bly)
25 Liters per hour at 39 psi
Fuel Filters 30 micron in-tank
Fuel Injector Visteon
EFI Controller Visteon
Fuel Capacity / Require-
ment
4.12 gal. (15.6 L)
87 (minimum)
89 Oxygenated
Electrical
Alternator Output 350 watt @ 5000 RPM
Voltage Regulator 3-phase
Lights : High Beam 50 watts
Low Beam 37 watts
Brake 26.9 watts
Tail 8.26 watts
Parking Lights 5 watts x 2
Turn 10 watts

1.11
GENERAL INFORMATION
1
Ignition Timing 10°± 1° BTDC @ Idle RPM
Spark plug / Gap NGK BKR6E
.035 in. / .9 mm
Battery / Amp Hr Lead Acid - 30 Amp Hr
Circuit Breakers Fan 20 Amp
Harness 20 Amp
Fuel Pump-ECU 15 Amp
Instrument Cluster-Voltage
Regulator 6 Amp
Starting Electric
Instrument Cluster LCD Gauge / Pod Indicator
lights
ENGINE Drivetrain
(1000 ml)
Gear Ratio :
Low (Front/Rear)
Rev (Front/Rear)
High (Front/Rear)
7.70:1/23.91:1
7.00:1/21.74:1
3.41:1/10.57:1
Clutch Type PVT EBS
Belt 3211113
shock
Front / Rear
Toe Out 0-1/16 in / .0 - .159 mm
Wheels / Brakes
Front Wheel Size
12x6 Cast Alloy
Kenda BCLAW
25 x 8 - 12
Rear Wheel Size
12x8 Cast Alloy
Kenda BCLAW
25 x 12.5 - 12
Single Control
Hydraulic Disc
Brake Fluid Polaris DOT 4 Brake Fluid
A12MN50ET Clutching
Altitude
Shift
Weight
Drive Clutch
Spring
Meters
(Feet)
0-1800
(0-6000)
10 WHF
(5632283)
Green / Blue
(7041157)
1800-3700
(6000-
12000)
10 RH
(5630709
Green / Blue
(7041157)

1.12
GENERAL INFORMATION
MISC. NUMBERS/CHARTS
Conversion Table
°C to °F: 9 (°C + 40) ¸ 5 - 40 = °F 
°F to °C: 5 (°F + 40) ¸ 9 - 40 = °C
Unit of Measure Multiplied by Converts to
ft. lbs. x 12 = in. lbs.
in. lbs. x .0833 = ft. lbs.
ft. lbs. x 1.356 = Nm
in. lbs. x .0115 = kg-m
Nm x .7376 = ft. lbs.
kg-m x 7.233 = ft. lbs.
kg-m x 86.796 = in. lbs.
kg-m x 10 = Nm
in. x 25.4 =mm
mm x .03937 = in.
in. x 2.54 = cm
mile (mi.) x 1.6 = km
km x .6214 = mile (mi.)
Ounces (oz.) x 28.35 = Grams (g)
Fluid Ounces (fl. oz.) x 29.57 = Cubic Centimeters (cc)
Cubic Centimeters (cc) x .03381 = Fluid Ounces (fl. oz.)
Grams (g) x 0.035 = Ounces (oz.)
lb. x .454 = kg
kg x 2.2046 = lb.
Cubic inches (cu. in) x 16.387 = Cubic centimeters (cc)
Cubic centimeters (cc) x 0.061 = Cubic inches (cu. in)
Imperial pints (Imp pt.) x 0.568 = Liters (l)
Liters (l) x 1.76 = Imperial pints (Imp pt.)
Imperial quarts (Imp qt.) x 1.137 = Liters (l)
Liters (l) x 0.88 = Imperial quarts (Imp qt.)
Imperial quarts (Imp qt.) x 1.201 = US quarts (US qt.)
US quarts (US qt.) x 0.833 = Imperial quarts (Imp qt.)
US quarts (US qt.) x 0.946 = Liters (l)
Liters (l) x 1.057 = US quarts (US qt.)
US gallons (US gal) x 3.785 =Liters (l)
Liters (l) x 0.264 = US gallons (US gal)
Pounds - force per square inch (psi) x 6.895 = Kilopascals (kPa)
Kilopascals (kPa) x 0.145 = Pounds - force per square inch (psi)
Kilopascals (kPa) x 0.01 = Kilograms - force per square cm
Kilograms - force per square cm x 98.1 = Kilopascals (kPa)
(3.14)xR2x H (height) = Cylinder Volume

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